Archive for the ‘Bakery’ Category

What’s the Difference Between Baking Soda and Baking Powder?

May 5th, 2018
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They both help things rise, but there are a couple major differences

Both baking soda and baking powder are crucial ingredients when it comes to cooking “quick rise” baked goods like pancakes and muffins, but they’re actually both quite different products. So what exactly is the difference between them?

The way that baking soda and baking powder make foods rise involves some chemistry, but it isn’t actually too complicated. Baking soda is comprised entirely of sodium bicarbonate, which is a base that releases carbon dioxide when exposed to an acid like vinegar or buttermilk. These bubbles of carbon dioxide are what gurgles up from inside a grade-school science fair “volcano” when baking soda interacts with vinegar. If those bubbles happen to get trapped inside a baked good, it will rise too; this process is called “chemical leavening” (as opposed to biological leavening via yeast or physical leavening via steam).

But the baking soda-acid reaction happens immediately, which isn’t ideal for many baking recipes. If you’re making cookies and all the CO2 bubbles have dissipated by the time you put the pan in the oven, you’re gonna have some flat cookies. This is where baking powder comes into play.

All baking powder contains baking soda, but it also contains two additional chemicals: monocalcium phosphate (which releases CO2 when exposed to water, especially helpful when a recipe doesn’t call for anything acidic) and sodium acid pyrophosphate or sodium aluminum sulfate (which release CO2 when exposed to heat). So if you use baking powder, your baked good won’t only rise when it’s exposed to an acid; it’ll also rise when exposed to water, and it’ll continue to rise even more when the batter is put into the pan or oven; that’s why baking powder is referred to as “double acting.” As the batter continues to cook, the bubbles will “set,” and voila: a perfectly risen cupcake, like the ones served at these bakeries.





Removing added sugars in sweet baked foods

May 5th, 2018
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Food manufacturers will have more reason to reduce added sugars in their products once the new Nutrition Facts Label becomes mandatory, and that’s especially true for makers of sweet baked foods.

The Food and Drug Administration has mandated that a new Nutrition Facts Label include a line for added sugars, which is not on the current panel. Stevia and other high-intensity sweeteners, polyols like erythritol, certain corn syrups and some fibers are all ingredients that may be used in reducing added sugar in baked foods.

The F.D.A. last September proposed to extend the compliance dates for the Nutrition Facts and Supplement Facts label final rule. Under the proposal, manufacturers with $10 million or more in annual food sales would have until Jan. 1, 2020, to come into compliance, an extension from July 26, 2018. Manufacturers with less than $10 million would have until Jan. 1, 2021. The F.D.A. defines added sugars as those that either are added during the processing of foods, or packaged as such.

“Other than traditional breads and pastas, many grain-based foods contain sizable amounts of what would be considered added sugar,” said Eric Shinsato, senior project leader, sweeteners for Ingredion, Inc., Westchester, Ill. “Examples of these include sweetened cereals, pastries, cakes, cookies, crackers, bars and other snack items, and breakfast items such as pancakes, waffles, muffins and quick breads.

“A typical chocolate chip cookie contains 11 grams of sugar per 33-gram serving while a carrot cake has 31 grams of sugar per 90-gram serving. A sweetened cereal can contain 11 grams of sugar per 30-gram
serving. So some of our favorite treats are about one-third sugars.”

Bill Gilbert, certified master baker, principal food technologist for Minneapolis-based Cargill, added, “American bakery products are among the sweetest in the world. Treats like cakes and cookies tend to contain the most sugar in our bakery product lines, but they’re certainly not alone. We’ve built our expectations on indulgent snacking and tend to lean toward sweeter products, with consumption throughout the day — from donuts or muffins in the morning and cookies mid-day to the slice of cheesecake in the evening.”

Many cookies have a high amount of sugar, said Mark Floerke, project lead, bakery and culinary applications for Archer Daniels Midland Co., Chicago.

“This would include waffle cones, ice cream cones, wafers and traditional cookies like chocolate chip, sandwich cookies and even many of the protein breakfast cookies and bars that are popular today,” he said.

The two categories that account for the most added sugars in the American diet are beverages (47%) and sweets and snacks (31%), according to the Dietary Guidelines for Americans 2015-20 (see chart on Page 32). Snacks and sweets include grain-based desserts such as cakes, pies, cookies, brownies, donuts, sweet rolls and pastries. Other examples of snacks and sweets are dairy desserts such as ice cream, other frozen desserts and puddings; candies; sugars; jams; syrups; and sweet toppings.

Bulk and sweetness

Makers of sweet baked foods, when replacing added sugar with other ingredients, must be concerned with more than sweetness.

“Sugar is perhaps one of the most misunderstood, or poorly understood, ingredients with consumers,” Mr. Floerke said. “The first thing we think of is that it makes things sweet, and yet that is probably one of the least important functional characteristics of sugar in all foods.”

Formulators do need to identify what will sweeten a product with reduced sugar. ADM offers high-intensity sweeteners, natural sweeteners, extracts and distillates, natural flavors, and nut butters, Mr. Floerke said.

Functionality and bulk also must be added back in when taking out added sugar. ADM offers glycerin, erythritol and modified starches. ADM/Matsutani, L.L.C., a joint venture between ADM, Matsutani Chemical Industry Co. Ltd. and Matsutani America, Inc., offers Fibersol soluble corn fiber.

“For traditional sugar cookies, spread, browning and texture are key attributes that can be managed really well using Fibersol,” Mr. Floerke said. “Softening of texture and/or general humectancy can be aided with addition of glycerirn. For cupcakes and muffins, the approaches may differ slightly for the bulking ingredients, as additional functionality may be needed in the mixing process. Adding emulsifiers like lecithin and/or soy protein isolates can also help with creaming and aerating the batters.”

Even when sugar is reduced, consumers have high expectations for both taste and texture, Mr. Gilbert said.

“Adding to the challenge, sugar is very functional in these applications,” he said. “Beyond taste, sugar impacts spreading in cookies, binding in granola bars, tenderness in cakes, browning and more. To achieve sugar reduction goals in these applications, product developers need to recreate this functionality by leveraging other ingredients.”

To replace sugar’s bulk, formulators might choose polyols like erythritol, reduced-sugar corn syrups, maltodextrins, corn syrup solids or even chicory root fiber, he said.

“These bulking agents can aid with tenderness, spread and mouthfeel but will need help from a high-intensity sweetener to replace sugar’s sweet taste,” Mr. Gilbert said. “Here, label-friendly stevia sweeteners are the clear choice.”

Cargill offers ViaTech stevia, Zerose erythritol and Oliggo-Fiber chicory root fiber.

“Stevia sweeteners are gaining popularity among consumers as clean label and naturally based sweeteners,” said Afrouz Naeini, senior marketing manager, sweeteners and beverage for Ingredion.

More bakery products, particularly the high-protein options, are being formulated with stevia sweeteners.

“Replacing the sweetness experience of sugar at high levels can be daunting,” Ms. Naeini said. “Best results can be achieved by replacing sugar with next-generation stevia sweeteners that allow for highest levels of sugar reduction without imparting any bitter aftertaste.”

Bestevia Reb M offers more sweetness compared to Reb A products with no bitter aftertaste. Ingredion distributes Bestevia Reb M, which is made by SweeGen, Inc., Rancho Santa Margarita, Calif.

“It allows formulators to build back up to 100% of the sweetness of sugar that is being replaced,” she said.

Clean label is a matter of perception in many instances because no regulated definition for clean label exists, Mr. Floerke said.

“If traditional replacement solutions do not meet the applicable clean label definition, then first understand the primary, and possibly secondary, functions of the ingredient,” he said. “With this information in hand, then working with your ingredient supplier will have far greater chances of success. Stevia and natural flavors that enhance sweetness and mask bitter notes are the first most obvious choices.

“Soluble corn fibers, glycerin, lecithin, bean powders, chickpea flour, as well as nut butters and peanut flours, are all good candidates to provide functionality needs in various applications.”

Will consumers notice?

The Dietary Guidelines for Americans recommends limiting added sugars to less than 10% of total calories, but on average Americans eat 270 calories of added sugar per person per day, or more than 13% of total calories.

“Strong evidence from mostly prospective cohort studies, but also randomized controlled trials, has shown that eating patterns that include lower intake of sources of added sugars are associated with reduced risk of CVD (cardiovascular disease) in adults, and moderate evidence indicates that these eating patterns are associated with reduced risk of obesity, type 2 diabetes and some types of cancer in adults,” the Dietary Guidelines said.

Yet including a line for added sugars on the Nutrition Facts Label may have a limited effect on consumers, according to a Corbion study of 800 U.S. consumers. Corbion, which has a U.S. office in Lenexa, Kas., divided the consumers into two groups: a low-intent group of people less likely to read product labels and a some-intent group of people that ranged from being more likely to read labels to being “extremely passionate” about reading labels.

People were shown the current Nutrition Facts Label and not given any aid on what to look for in the panel. Among the low-intent group, 13% said sugar content would influence their purchase decision. Among the same-intent group, 19% said sugar content would influence their purchase decision. When both groups were shown the current Nutrition Facts Label next to the upcoming Nutrition Facts Label, the percentages rose to 20% for the low-intent group and 25% for the some-intent group.

“The key is, for both sets of numbers it is not statistically significant,” said Marge O’Brien, senior manager, global insights for Corbion, in a Feb. 26 presentation at the American Society of Baking’s BakingTech 2018 in Chicago.



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Bakery China 2018

May 5th, 2018
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With an exhibition area of over 200,000 square meters this year, Bakery China 2018, to be held on May 9-12, has attracted more than 2,100 exhibitors from all over the world.

As an important indicator of China’s robust growth on bakery, Bakery China ( was launched 21 years ago and has developed into the world’s largest exhibition in this area. As the organisers of this high-profile and impactful event, China Association of Bakery & Confectionery Industry (CABCI) and Bakery China Exhibitions Co., Ltd. will welcome more than 140,000 professional visitors from over 110 countries and regions at the Shanghai New International Expo Center for Bakery China 2018, where every participant will truly experience the vibrant prosperity and innovation of China’s bakery industry.

China’s bakery industry, which has been experiencing a rapid growth since the end of last century, boasted a 20% average growth rate between 2003 and 2016 and is emerging as a global leader in the industry. In the forthcoming months, the country is expected to become the largest producer and consumer of bakery products. According to statistics on bakery enterprises above state-designated scale from the National Bureau of Statistics of China, in 2017, China’s bakery and confectionery production (including pastry/breads, biscuits, chocolates, frozen beverages, instant noodles and sweetmeats) totalled 35.899 million tons, with a prime operating revenue of RMB 743.178 billion, at a year-on-year growth of 8.29%.

As indicated by CABCI, based on a population of 1.37 billion, China’s per capita annual consumption of bread in 2017 was only 4.4kg. Compared to an average of 10kg in South Korea, over 20kg in Japan and over 70-80kg in the US and Western European countries, it is obvious that China holds great potential of growth and expansion. Fast urbanisation and diversification of people’s diets will be the key drivers for the growth of the bakery industry in China.



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Study reveals consumers’ favourite bread

April 14th, 2018
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Comax Flavors has released new primary research on consumers’ preferences towards bread products.
Slightly less than half the respondents preferred whole wheat as the number one flavour consumed by all generations. Second favourite was white bread, with multi-grain only cited as a favourite by a third of the respondents, by 22 per cent. 85 per cent of 1000 U.S. respondents prefer eating a closed sliced bread sandwich compared to 16 per cent who eat it open-faced.

Among all generations, the baby boomers are the heaviest rye bread consumers compared those between 20 to 30 years of age who do not consume it. Sourdough and rye bread were equally popular by 14 per cent of the study’s respondents.

The surprising element was how price played a more important role than flavour, with consumers selecting cost over taste, according to Comax Flavor’s study. 57 per cent of respondents cited “taste” as only the second most important attribute when buying sliced bread.

Bread is a staple of many North Americans’ diet, but consumers are eating it less frequently and in smaller quantities. According to IRI data for 52 weeks, ending June 11, 2017, there was little change in the overall bakery sector, with a mere 0.1 per cent rise to $13.31 billion U.S. from the year prior.

“We recognize that the bread market is stagnant. Consumers are gravitating towards low-calorie, whole grains, artisanal and gluten-free breads and we wanted to better understand what’s happening among the general population,” stated Catherine Armstrong, Vice President of Corporate Communications for Comax Flavors, in a press release.

The bread study was fielded in September 2017 with 1,000 U.S. respondents aged 18 to over 70, evenly distributed between male and female.


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The fight to find organic flour

April 14th, 2018
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Demand for organic products has been growing by double digits since the 1990s, according to the Organic Trade Association. Mintel considers non-GMO to be one of the fastest-growing claims with 44% of new food products between 2013 and 2016 claiming to be non-GMO.

Despite this, farmers haven’t kept up the supply of USDA-certified organic wheat or Non-GMO Project verified corn and other grains. (Wheat is not a genetically modified crop.)

“The biggest challenge around sourcing organic flours and seeds is overall supply,” said Harold Ward, director of technical service and product applications at Bay State Milling Co. “A good example of this would be organic wheat. Of the wheat planted in the U.S., less than 1% is organic. Much smaller supply means less choice from the standpoint of functionality and other target characteristics.”

Offsetting supply issues

Organic and non-GMO certifications are expensive and time consuming to achieve even though those ingredients sell at a premium. Growers must make a significant commitment to and investment in the transition from conventional farming to organic and non-GMO crops, not to mention the transition period before farmers can see a return on their investment. These barriers to entry mean that the supply of organic wheat and non-GMO grains is slim compared to conventional.

Additionally, if there is a tough year for crops, flour suppliers have less organic supply to offset undesirable characteristics.

“Because we’re talking about working with a much smaller supply of wheat, in a given crop year, you could see lower or higher protein levels or ­possibly substantial changes in functional characteristics such as absorption or mixing tolerance,” Ward explained.

These issues still happen with conventional crops, but because of the vastness of that supply, millers can overcome those issues with blending to provide bakers consistent flour. The smaller the supply, the more difficult it becomes to meet these bakers’ needs.

Ward doesn’t believe this will be a permanent issue for organic bakers. Consumer demand and support from millers will push farmers to grow more fields organically. In the meantime, however, he encouraged bakers to be mindful when formulating for organic ingredients.

“Build formulas that are adaptable and robust enough to cope with possible changes,” he said. “Keeping an open mind when it comes to process adjustments and using ingredients that will enhance functionality or provide needed protein is very important. I also suggest partnering with your supplier so you have a clear line of sight to current crop characteristics as well as what is on the horizon.”

Bay State Milling’s product applications and R&D teams work with bakers to develop products using these organic ingredients and are available to help address these potential issues.

Ardent Mills anticipates that its organic program will expand to support an organic supply chain for the baking industry.

“Our extensive organic grower network, milling and storage locations allow us to provide a consistent reliable and quality organic flour that bakers can count on,” said Shrene White, ­general manager, The Annex by Ardent Mills. “It’s a good time to come into organic.”

Weakening barriers to entry

Solving the issue of supply largely rests in the hands of farmers. They need to make the commitment to become certified organic growers. However, the certification process and transition from conventional farming to organic can be intimidating and expensive.

Many flour millers see it as their responsibility to support farmers in their transition to organic as it improves the supply and quality of organic wheat, corn and other grains. Ardent Mills, for example, created the Organic Initiative 2019. Launched in 2015, the program’s goal is to double the amount of organic wheat acreage in the United States by next year.

“As a part of the strategy, we launched a series of farmer meetings in North Dakota, Colorado and Idaho to identify producer concerns about converting to organic and to help shape our initiative,” White said.

Through those meetings, the company gauged farmers’ greatest concerns, including education, changing practices, disease and pest control, as well as rotational and cover crops.

“We all need to be aware that the transition is not going to happen overnight, and Ardent Mills wants to help farmers and manufacturers meet the demand for organic foods,” White said.

The three-year transition period to organic remains one of the biggest barriers to entry for many farmers. A field that was previously farmed conventionally needs three years being farmed organically before any crops grown can carry the USDA-organic certification. During that time a farmer will invest all the time, energy and money necessary to farm organically without getting the payoff of that premium price.

“It has been an ongoing issue in the organic industry for supply to keep up with growing demand,” said Jennifer Tesch, chief marketing officer, Heathy Food Ingredients (HFI). “We believe through continued education to growers about the opportunities within the organic and non-GMO markets, more producers will transition from conventional to organic.”

To ease that transition cost, some Accredited Organic Certifying Agencies (ACAs) such as Quality Assurance International offer transitional organic certification. In fact, HFI became the first certified transitional ingredient supplier with a hard red winter wheat processed by its brand Hesco/Dakota Organic Products. Tesch said that the company’s relationship with growers allowed the company to guide them in the certification process.

“The transitional certification is beneficial to growers because we now have a market for these growers’ crops during the three transitional years, and they can be compensated with a premium during the costly conversion to organic,” she said.

Bunge North America also recently began offering certified transitional ingredients; in this case, dry milled corn ingredients. The company pays farmers a premium for this corn during that three-year period.

“The certified transitional market gives farmers an opportunity to sell this corn at a premium during their shift to certified organic, incentivizing them to make the move into organic farming,” said Gregg Christensen, vice-president of sales for Bunge Milling. “Bunge is taking the lead in corn by connecting farmers who are interested in certified transitional products as a way of building a more scalable and reliable future ­supply of organic products.”

While many ACAs offer their own certified transitional organic programs, the Organic Trade Association is working with the USDA to unify these standards into a nationwide program — the National Certified Transitional Program.

Source: World Grain


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Campden BRI bread structure measurement method internationally approved

April 7th, 2018
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Campden BRI’s method “Use of C-Cell to Measure Cell Structure of Baked Goods” has been accepted as an Approved Method by AACC International (AACCI), the leader in grain-based analytical methods for the food industry since 1922. The method will help bakers to objectively assess quality.

Crumb structure characteristics of bread and other baked products are traditionally measured subjectively, but this new AACCI Approved Method uses the C-Cell digital imaging system to objectively characterise internal crumb structure characteristics. This could be used, for example, by bakers to measure their products against set specifications.

Previously the method was only available to Campden BRI members, but it is now also available via subscription from AACCI as Approved Method 10-18.01.

The method was validated by a collaborative study conducted by Campden BRI’s CCAT (Cereals and Cereals Application Testing) working group, with help from eight UK laboratories. The laboratories used their own instruments to collect and validate the C-Cell data for six parameters that are most applicable to baked product characteristics.

Clothilde Baker, Ingredients and Primary Product Characterisation Manager, said, “We are pleased that this method is now an approved AACCI method available to all via the AACCI Approved Methods of Analysis, 11th Edition. We would like to thank all the members of the CCAT working group for allowing AACCI to publish this method. We would also like to thank all the companies that participated in the validation of this method: AB Mauri UK and Ireland Ltd, Allied Technical Centre Ltd, Calibre Control International Ltd, GB Plange UK Ltd, University of Manchester and Warburtons Ltd.”

C-Cell method

C-Cell produces over 50 measurements per analysis, these are broken down into the following sub-groups to determine product quality in bread.

  • Colour
  • Dimensions
  • Shape
  • Cell Size
  • Elongation
  • Inclusions
  • External features
  • Bread score

Many bakeries select 5-8 results that best differentiates their product quality.


L*a*b* Colour results are available with C-Cell Colour. Data such as average crumb colour, external crust colour and brightness of the crumb are available. The ‘crust unwrap tool’ is featured here which also enables the crust thickness to be measured.

Multiple measurements are recorded for each slice including slice area, height, width and packaging dimensions such as a wrapper length.


Visual appearance is quantified with shape measurements, such as the Concavity (top, bottom and side), Oven Spring (position, height, depth) and top shoulder and bottom roundness.

Bread score
As bakers produce different types of product at C-Cell we have developed a scoring system to combine results into one specific score which relates to the sensory assessment of the particular bakery product. Bakeries use this to monitor changes in batch production and identify variability on a daily basis.

Cell SizeIndividual cell analysis provides detailed information regarding number, size and distribution of cells throughout the crumb structure. Holes, Wall Thickness and Cell Areas & Volumes are quantified.
ElongationMoulding performance can be monitored through crumb cell elongation measurements. C-Cell gives a visual circulation map showing the axis of elongation and level of curvature of the internal crumb structure in addition to a specific degree of circulation result.



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The most popular baked goods flavours for 2017

April 7th, 2018
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Comax Flavors has released new market research on American consumers’ behaviour towards baked goods. The study focused on cakes, cookies, donuts, muffins and pies.
The Sweet Baked Goods study was fielded in August 2017 with 1,000 U.S. respondents between the ages of 18 to over 70; half were female and the other half were male.According to IRI, the pastry/danish/coffee cakes segment grew by 3.5 per cent to $2.0 billion, doughnuts were up 2.7 per cent to $2.0 billion and muffin sales were up 8.3 per cent to $976.6 million in the United States for the 52 weeks ending March 19, 2017.

“Although there has been a lot of activity in better-for-you products, consumers still have a sweet tooth and crave a variety of baked goods,” stated Catherine Armstrong, VP of Corporate Communications for Comax Flavors in a press release. “We wanted to better understand what’s happening in baked goods among the general population.”

The most popular flavours are, in order of popularity:

  1. Chocolate
  2. Chocolate-chip
  3. Red Velvet
  4. Berry and coconut flavours
  5. Apple

When it comes to cookies, 74 per cent of all respondents preferred a soft or chewy cookie. Half or more of all respondents like a filled, sandwich style cookie. 68 per cent of the study selected the chocolate chip cookie as their favourite.  In second and third place were oatmeal and peanut butter cookies respectively, while Generation Z prefers candies in their batter, such as M&M’s.

More than half of the study responded that they preferred glazed donuts, and powdered sugar coming in second to topping favourites.  Chocolate and chocolate-frosted were the most popular choices in the glazed category. 26 per cent of the respondents consume jelly filled donuts, particularly among those who are over the age of 70.

According to the study, the most popular muffin flavour is blueberry across all age ranges, with chocolate chip coming in second. Banana muffins came in third, with chocolate muffins and coffee crumb muffins nearly tied for fourth place in flavour popularity.

The Sweet Baked Goods study cited apple pie as the “number one universally consumed flavour by all generations,” with 68 per cent citing it as their favourite. The second most loved pie is Cherry.

Among pastry lovers, the cheese danish was the most popular, and the pecan danish the least favourite. Among cupcake fans, only three-quarters consume chocolate and half consume cream-filled cupcakes. Less than half (46 per cent) of the respondents eat Red Velvet.

To request a copy of the complete Sweet Expectations infographic, contact or get more information from


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Award-Winning Equipment

April 7th, 2018
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Convenience and efficiency are key words to describe the latest innovations in bakery oven and cooking equipment for bakeries and foodservice operations.

Winner of a best new product award at Europain 2018, the software tool MIWE shop baking suite (MIWE sbs) allows you to manage, monitor and synchronize your baking systems’ data remotely and to benefit from the opportunities of networked systems. Consisting of interconnected modules, the software suite represents an extremely versatile toolbox for not only branch and regional managers, but also master bakers, administrators and quality managers.

MIWE sbs allows you to map your own organizational structure and to centrally manage and distribute your baking programs, so that all ovens belonging to the same profile can be supplied with the same information at the click of a button. A regional manager can thus easily organize baking operations in all branches, such as setting the autostart or cleaning times or deciding which image is to be shown in eco mode.

Baxter is introducing the VersaOven, a new type of kitchen equipment that combines the best features of rotisserie, convection and combi ovens into a space-saving oven category all its own. Built with patent-pending technology to offer versatility, performance and intuitive operation, the VersaOven enables cooking, baking and steaming without the difficulty of operation that can come with combi ovens, or the arduous cleanup that can be a hallmark of convection ovens.

“The Baxter VersaOven is truly unique because it handles so many kinds of food and styles of cooking with terrific results,” says chef Michelle Bridges, Baxter’s manager of bakery/culinary support. “Cooks of all skill and experience levels can easily use the VersaOven to cook racks of rotisserie-style chicken, steam vegetables and bake moist, flavorful cakes.”

The National Restaurant Association recently announced recipients of the 2018 Kitchen Innovations (KI) Awards, honoring progressive equipment that increases efficiencies and productivity for back-of-the-house operations and benefits restaurant operators. Each recipient and their product will be showcased in the interactive Kitchen Innovations Showroom at the 2018 National Restaurant Association Restaurant, Hotel-Motel Show, to be held May 19-22 in Chicago at McCormick Place.

The 2018 KI Award recipients reflect the trends and topics most important to foodservice operators today. The 22 selected innovations address operator concerns from labor, energy and water efficiency to food safety, sanitation, cross-functionality and space-saving. New software and new materials continue to make new solutions possible.

The 2018 Kitchen Innovations Award recipients in baking and cooking include the following:

Alto-Shaam, Inc.
Vector F Series Multi-Cook Oven
Features larger chambers to accept full size sheet or hotel pans.

GST-1H Flatbread-Toaster
Wide-mouth loading and dual platens located inside dual conveyor belts heat a variety of products consistently.

Evo, Inc.
MultiZone Plancha
Offers three independent cooking zones, each separated with IsoBar technology, which mitigates temperature carryover.

Level RF Oven
Employs radio frequency cooking to cook foods to prescribed standards for internal temperature, surface doneness, etc.

Marra Forni
Electric Brick Oven with Open Mouth
Provides cooking temps up to 1000°F, cooking a pizza in 45 seconds.

Source: Bakemag


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Handling Automation: Working with Trays and Pans

April 7th, 2018
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Product carriers play an important role in baking facilities. Bakeware specialist Kempf shares expertise on working with trays in baking facilities, and on what benefits different types of trays bring to the manufacturing line and operations – to best match them with the product.

Support trays for the baking industry come in a variety of materials and shapes. Customization is key as it greatly impacts process results and the end product characteristics. “Support trays and pans can be customized to fulfil the technical requirements of baking lines and products by using different materials on frames, baking surfaces and coatings,” Humberto Karam explains. To recommend optimum specifications, Kempf follows basic engineering rules as well as over 40 years of experience it accumulated in the bakery sector.

There are innumerous possible customs designs that can be achieved with bakeware, each with its functionalities to best match the production environment. Here are the main ones, according to the specialist from Kempf:

  • “Convoluted trays for baguettes and other products with a similar shape: stainless-steel frame; aluminum screen with different sizes of round perforations; different coating solutions.
  • Flat top trays for various types of bread and pastry products: stainless-steel frame; solid or perforated aluminum screen; fixation with or without rivets; various coating solutions.
  • Indented trays for long shelf-life croissants and buns: stainless-steel frame; alu-steel top; special Teflon coating.
  • Tin sets for breads and cakes: deep-drawn alu-steel tins; different number of tins and configurations.


– Stable profile frame with “edge bumper”

– Single corrugated tins

– Perforated tins

– Double or reinforced frame

– Matching lid with vents

  • Peelboards made of different materials, such as plastic or coated metal; textile-free; hygienic; easy to clean.
  • Several types of non-stick coatings: fluoropolymers (e.g. Teflon) and silicone-rubber.”

Trays for the right process

On new developments of industrial bakeware, Kempf usually tests its trays or tin sets at the facilities of the manufacturer of the line or at the customers’ plants. “On coatings, we also carry out tests at the labs of our suppliers of raw materials. We cooperate with all key players involved in the process,” explains Karam.

The different materials used for trays each brings their own sets of benefits. Aluminium alloy AlMn trays are flat and convoluted, either solid or perforated. They allow excellent heat transfer, are very light weight and moldable while retaining the desired shapes for a long time. This type of trays is rustproof and optimal for non-stick coatings.

Alusteel (FAl) or aluminized steel is used for deep-drawn tins and indented pans. This, too, allows for great heat transfer and is excellent for deep-drawing process (deep tins/pans). It is highly resistant to heat, which is importing for recoating of tins, explains the specialist. This material makes tins/pans robust (shock-resistant), and optimal for non-stick coatings – they can be recoated several times.

Stainless-steel is the material generally going into trays and frames of industrial trays. It’s “great for building frames of industrial trays, as it is very robust, long lasting and reusable”. Stainless steel also comes with the benefit of being rustproof.

Product handling

While a wide range of product categories can share the same type of trays/pans, here are some suggestions of how they can be grouped (keeping in mind that “there are many product categories and possibilities,” underlines Kempf’s representative):

  • Crusty breads, ciabatta: flat and convoluted trays
  • Sandwich bread, loaves, cakes, etc.: tin sets
  • Hamburger and hot-dog buns: indented trays

As for handling during manufacturing, the bakeware and coatings made by the German specialist can be adapted “to work with almost all depanning processes (pushers, fingers, vacuum, etc.)”.

A close look at coatings

How should coating types be chosen, according to products manufactured and manufacturing equipment/processes? Given that there are so many the factors to be considered, “there is no one-size-fits-all solution,” warns Karam, and this is where the line and product manufacturer can decide together. Here are two examples.

Characteristics of silicone rubber coatings include:

  • Heat resistance up to 300°C;
  • Hygroscopic properties;
  • Non-stick and anti-slip properties: often important to avoid that frozen products move and fall from the trays while being moved on the line;
  • Only for baking trays;
  • Available colors: red and grey.

This coating is very popular on convoluted trays for the production of crusty products, such as baguette; it can also be used on flat trays for crusty products.

Fluoropolymers have the following benefits:

  • High abrasion and heat resistance;
  • Great cost/benefit ratio;
  • Extended release life;
  • Improved sanitation;
  • Many customized solutions, according to the products and process, but also the customer’s budget.

Tray automation

Kempf can offer many different solutions, according to the system and the products. “We can adapt to most technical requirements of our industry. However, we see a trend towards using more elaborated fluoropolymers, such as our KG-Flon 704 green, which is a great Teflon, full of benefits for our customers:

  • Special and complex application process
  • Excellent non-stick properties
  • Heat resistance around 270°C
  • Outstanding durability
  • Can achieve over 5,000 releases!
  • Very often achieving 3x more baking cycles than other coatings
  • Especially suitable for industrial bakeries: pans/tins and trays
  • Easy-to-clean.”

As production lines are increasingly becoming automated, this will also include handling with trays – processes that help with labor costs, save time and resources. Karam explains: “We strongly believe that a great coating can make a huge difference. There is a lot of high-technology involved in the development of fluoropolymers and its application. Kempf has been investing a lot of resources in the modernization of our automatic coating lines, which are certified by Chemours (see below) and for sure one of the most modern in Europe. We continue to work close together with our suppliers to look for innovative solutions that make our bakeware better.

  • TIBS: Teflon Industrial Bakery Solutions
  • Licensed applicator & marketer of Chemours Teflon Coatings for bakeware
  • Exclusive Partner for Germany
  • Access to new developments
  • Strict specifications on quality, process and equipment
  • Several joint developments.”

Source: World Bakers


Bakery, Processing , ,

The Growth of Women in Retail Bakeries

March 17th, 2018
Comments Off on The Growth of Women in Retail Bakeries

March 8 is International Women’s Day, a time to celebrate the social, economic, cultural and political achievements of women. It’s also a time to recognize that there is still much work to be done in accelerating gender parity.

The food industry has been considered by many to be on the forefront of this movement, with nearly half of its entry-level workforce being comprised of women. However, not all is satisfactory, as less than one-fourth of upper level industry positions are held by women.

Retail bakeries are one area within the industry that is making great strides in increasing the representation of women. According to our 2017 Retail Bakery Operations Study, 54 percent of those surveyed were women, up from 49 percent in 2012.

The future is bright for retail bakeries thanks to these women, who are leading the way in innovation. Total industry revenue rose an estimated 7 percent from 2016, and much of that can be credited to the creativity of the industry’s strong female representation.

In Montclair, New Jersey, Montclair Bread Company owner Rachel Crampsey innovates by conducting a host of events (a spring street fair, artisan bread/donut classes, summer baking camp, annual 5K donut run) that intertwine local customers into the fabric of the community and this neighborhood bakery. Montclair Bread’s clever catchphrase, “Fueled by Doughnuts,” helps build brand exposure for this bread bakery with a donut addiction.

“With bread, you can be part of someone’s family every day, whether it’s someone’s toast in the morning or the dinner table at night. It is part of people’s daily existence,” says Crampsey.

Joanne Chang of Flour Bakery + Café is bringing a renewed commitment to whole grains at her bakery’s seven locations with the WHOLEflour line of whole grain-based cookies, brownies, scones, croissants, and more.

“Today’s consumer is knowledgeable and curious and opinionated about what they eat and put in their bodies,” Chang says. “Offering products with whole grains is hugely important. In the same way we’ve added vegan and gluten-free options to our menu, now we have whole grain items and our guests appreciate these and benefit from them.”

This forward thinking has made Joanne Chang one of the top names in baking in the country, and has put Flour Bakery + Café on the map as a premiere bakery destination.

Sunday, March 4 saw business leaders join together at the Women’s Foodservice Forum in Dallas, Texas to kick off its efforts encouraging the food industry to “Lead the Way” to gender equity. While retail bakeries still have much work to do in achieving this parity, the progress that has been made in recent years is very encouraging.

Source: Bakemag